NEW EXPECTATIONS

GRANITEN FLEXLINE PACKAGING PLATFORM

Pharma producers of today often struggles with their order batches getting smaller.

A few changes can be attributed to this, including the rapid progress in research and advancements in medicine that has led to new targeted therapies, speciality pharmaceuticals and personalised medicine.

Each market also has specific requirements that manufacturers must adhere to, in terms of product formats, packaging and labelling. This further breaks down each manufacturing batch into smaller orders batches, requiring more and more changeovers.

These trends indicate that order sizes are decreasing, in some cases as much as 70% of batches being less than a few hundred units.

With more frequent and lengthy changeover times from one batch to another, high speed legacy lines can only deliver a fraction of their full capacity. Changeovers have been reported as taking up as much as 80% of production time, severely compromising the equipment’s efficiency.

Production planning becomes focused on the limitations of the production equipment rather than on market needs.

TIME TO MARKET

In the past, automated systems were closely designed around the physical formats of the products and tailored to very high volumes. Introducing new formats is complex and time consuming, or even impossible. It is also very difficult to adapt existing machinery to new requirements, i.e. an additional labels, serialization etc.
Validation of new or adapted production equipment often takes almost as long as designing and manufacturing the equipment.

WHAT IF..?

…there was a production line that could be setup for different formats within minutes?

… there was a production line that where a wide range of new formats and patterns can be easily introduced?

… there was a production line that is built truly modular where each process step can be validated separately?

… there was a production line where new modules can be easily added as needs change?
This would enable a payback in 1 day vs current production machines

To enable higher OEE, instead of focusing on parts per minute we need to change our mindset towards the more important, and relevant batches per shift.

Why have fast legacy lines that need to rest for long times during the race?

Now, with Graniten’s new Flexline Packaging Platform, which only need minutes to set up for a new run, a high number of orders can be run even if the volumes are low

The Graniten Flexline enables payback in days for small batches production of high value products!

The Graniten Flexline Packaging Platform help ensure continuing production by allowing manufacturers to move their small order runs off the legacy, high-capacity lines, thereby reducing the amount of long and costly changeovers needed leading to higher asset and line capacity utilization.

COMPLETE PACKAGING REFORM

MODULARITY

Each process step is in a separate module. Based on your requirements, modules that fit the functions needed are configured together forming your packing line. With its flexible modular setup. the Graniten Flexline platform fits with most production and packing needs allowing you to get a tailormade setup.

It offers investment protection, as modules can be replaced or added as new production needs arise. Modules can also be pre-validated before installation resulting in quicker time to market.

Flexline modularity enables high usage of invested assets over time since the machine can be easily adjusted for new products, increasing ROI

FLEXIBILITY

Low speed, close to zero (C2Z) change-over time between format recipes
10-20 products/min

< 3mins Change-over for bottle line
< 15 min for vials, syringes and autoinjectors
< 15 min for Blisters
Easy to add new format recipes.
Wide format range
Different sizes and shapes of products can be handled with no format parts.

APPLICATIONS

  • Vials
  • Bottles
  • Syringes
  • Auto injectors
  • Blister

MAIN FEATURES

  • Modular – fits with most production and packing needs allowing for a tailormade setup. Opt for all, or a variation of cells, for primary, secondary and/or tertiary (end-of-line) packing
  • Low Changeover Time – format changes done by recipes change only; it has close-to-zero (C2Z) change over time, allowing for a more continuous operation
  • Scalable & Upgradeable – new modules can be easily added or upgraded at a later stage as requirements and technology change and thereby extend the life of the investment
  • Ease of Setup of New Recipes – no physical parts needs changed between format changes, setting up new recipes becomes quick and simple
  • Prepared for aggregation and serialisation – Enables track and trace of batches and boxes, increasing regulatory and quality compliance and enables better management of your supply chain
  • Close integration with factory production planning and line supervision systems

WHY FLEXLINE

BECAUSE IT TAKES A HOLISTIC APPROACH OF THE GROWING PAIN POINTS IN PHARMA PRODUCTION

Order Sizes are going down, more focus on inventory costs

Flexline decreases chege over time to increase overall productivity

Incrasingly

Biological drugs will drive more comlex/ controlled manufacturing methods

Flexline decreases chege over time to increase overall productivity

Precision/

Personalized medicine is increasing and will continue to increase

Fliexine meets the need for more compact production equipment with more functionality

Pharmaceuticals are getting more and more expensive (eg. biologicals)

Flexline offers late stage customization – ”Lot Size One”